Multi-layer work function metal gates with similar gate thickness to achieve multi-vt for vfets

ABSTRACT

A method is presented for forming a device having multiple field effect transistors (FETs) with each FET having a different work function. In particular, the method includes forming multiple microchips in which each FET has a different threshold voltage (Vt) or work-function. In one embodiment, four FETs are formed over a semiconductor substrate. Each FET has a source, drain and a gate electrode. Each gate electrode is processed independently to provide a substantially different threshold voltage.

BACKGROUND Technical Field

The present invention relates generally to semiconductor devices, andmore specifically, to multi-layer work function metal gates with similargate thickness to achieve different threshold voltages for each fieldeffect transistor (FET).

Description of the Related Art

There is great difficulty in maintaining performance improvements indevices of deep submicron generations. Thus, methods for improvingperformance without scaling down dimensions have become of interest.There is a promising avenue toward higher gate capacitance withouthaving to make the gate dielectric thinner. This approach involves theuse of high-k materials. The dielectric constant of such materials ishigher than that of silicon dioxide (SiO₂). A high-k material canphysically be thicker than an oxide and still have a lower equivalentoxide thickness (EOT) value.

High performance small field effect transistor (FET) devices are in needof precise threshold voltage control. As operating voltage decreases,threshold voltages also have to decrease, and threshold variationbecomes less tolerable. Every new element, such as a different gatedielectric, or a different gate material, influences the thresholdvoltage. Techniques exist to tune device thresholds through themodification of the gate work function.

SUMMARY

In accordance with an embodiment, a method is provided for forming adevice having multiple field effect transistors (FETs) with each FEThaving a different work function gate stack. The method includes formingfirst, second, third, and fourth FETs over a semiconductor substrate,forming an interfacial layer and a high-k dielectric layer over thefirst, second, third, and fourth FETs, forming a first work functionconducting layer over the high-k dielectric layer, and removing thefirst work function conducting layer from the third FET. The methodfurther includes depositing a second work function conducting layer,removing the first and second work function conducting layers from thesecond FET, depositing a third work function conducting layer, removingthe first, second, and third work function conducting layers from thefirst FET, and depositing a fourth work function conducting layer. Themethod further includes depositing a sacrificial block layer and asacrificial cap layer, removing the sacrificial block layer and thesacrificial cap layer from the first and second FETs, depositing a fifthwork function conducting layer and a patterning cap layer, removing thepatterning cap layer, the fifth work function conducting layer, and thesacrificial cap layer from the third and fourth FETs, and removing thesacrificial block layer from the third and fourth FETs. The methodfurther includes depositing first and second conducting layers over thefirst, second, third, and fourth FETs, depositing a dummy fill material,recessing the dummy fill material, recessing remaining work functionconducting layers from the first, second, third, and fourth FETs toexpose a hard mask of each of the first, second, third, and fourth FETs,and stripping the dummy fill material. The method further includesdepositing a dielectric layer up to a top surface of the hard mask ofeach of the first, second, third, and fourth FETs, recessing thedielectric layer and forming spacers, performing isolation patterning ofthe first, second, third, and fourth FETs for isolation FETs, depositingan insulator between the recesses formed by the isolation patterning,and etching to expose a top portion of a channel of each of the first,second, third, and fourth FETs.

In accordance with another embodiment, a semiconductor device isprovided for forming a device having multiple field effect transistors(FETs) with each FET having a different work function. The semiconductordevice includes first, second, third, and fourth FETs formed over asemiconductor substrate, a high-k dielectric layer formed over thefirst, second, third, and fourth FETs, a first work function conductinglayer formed over the high-k dielectric layer, where the first workfunction conducting layer is subsequently removed from the third FET, asecond work function conducting layer, where the first and second workfunction conducting layers are subsequently removed from the second FET,a third work function conducting layer, where the first, second, andthird work function conducting layers are subsequently removed from thefirst FET, and a fourth work function conducting layer. The structurefurther includes a sacrificial block layer and a sacrificial cap layer,the sacrificial block layer and the sacrificial cap layer subsequentlyremoved from the first and second FETs, a fifth work function conductinglayer and a patterning cap layer, where the patterning cap layer, thefifth work function conducting layer, the sacrificial cap, and thesacrificial block layer are subsequently removed from the third andfourth FETs, and first and second conducting layers formed over thefirst, second, third, and fourth FETs.

It should be noted that the exemplary embodiments are described withreference to different subject-matters. In particular, some embodimentsare described with reference to method type claims whereas otherembodiments have been described with reference to apparatus type claims.However, a person skilled in the art will gather from the above and thefollowing description that, unless otherwise notified, in addition toany combination of features belonging to one type of subject-matter,also any combination between features relating to differentsubject-matters, in particular, between features of the method typeclaims, and features of the apparatus type claims, is considered as tobe described within this document.

These and other features and advantages will become apparent from thefollowing detailed description of illustrative embodiments thereof,which is to be read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The invention will provide details in the following description ofpreferred embodiments with reference to the following figures wherein:

FIG. 1 is a cross-sectional view of a semiconductor structure includinga first work function metal layer deposited over first, second, third,and fourth field effect transistors (FETs), in accordance with anembodiment of the present invention;

FIG. 2 is a cross-sectional view of the semiconductor structure of FIG.1 where a patterning block layer (or stack) is deposited and recessedaround the third FET, in accordance with an embodiment of the presentinvention;

FIG. 3 is a cross-sectional view of the semiconductor structure of FIG.2 where the first work function metal layer is removed from the thirdFET, in accordance with an embodiment of the present invention;

FIG. 4 is a cross-sectional view of the semiconductor structure of FIG.3 where a second work function metal layer is deposited, in accordancewith an embodiment of the present invention;

FIG. 5 is a cross-sectional view of the semiconductor structure of FIG.4 where a patterning block layer (or stack) is deposited and recessedaround the second FET, in accordance with an embodiment of the presentinvention;

FIG. 6 is a cross-sectional view of the semiconductor structure of FIG.5 where the first and second work function metal layers are removed fromthe second FET, in accordance with an embodiment of the presentinvention;

FIG. 7 is a cross-sectional view of the semiconductor structure of FIG.6 where a third work function metal layer is deposited, in accordancewith an embodiment of the present invention;

FIG. 8 is a cross-sectional view of the semiconductor structure of FIG.7 where a patterning block layer (or stack) is deposited and recessedaround the first FET, in accordance with an embodiment of the presentinvention;

FIG. 9 is a cross-sectional view of the semiconductor structure of FIG.8 where the first, second, and third work function metal layers areremoved from the first FET, in accordance with an embodiment of thepresent invention;

FIG. 10 is a cross-sectional view of the semiconductor structure of FIG.9 where a fourth work function metal layer is deposited, as well as asacrificial block layer, and a sacrificial cap layer, in accordance withan embodiment of the present invention;

FIG. 11 is a cross-sectional view of the semiconductor structure of FIG.10 where a patterning block layer (or stack) is deposited and recessedaround the first and second FETs, in accordance with an embodiment ofthe present invention;

FIG. 12 is a cross-sectional view of the semiconductor structure of FIG.11 where the sacrificial cap layer and the sacrificial block layer areremoved from the first and second FETs, in accordance with an embodimentof the present invention;

FIG. 13 is a cross-sectional view of the semiconductor structure of FIG.12 where an nFET work function metal is deposited, as well as apatterning cap, in accordance with an embodiment of the presentinvention;

FIG. 14 is a cross-sectional view of the semiconductor structure of FIG.13 where a patterning block layer (or stack) is deposited and recessedaround the third and fourth FETs, in accordance with an embodiment ofthe present invention;

FIG. 15 is a cross-sectional view of the semiconductor structure of FIG.14 where the nFET work function metal and the sacrificial cap layer areremoved, in accordance with an embodiment of the present invention;

FIG. 16 is a cross-sectional view of the semiconductor structure of FIG.15 where the sacrificial block layer is removed, in accordance with anembodiment of the present invention;

FIG. 17 is a cross-sectional view of the semiconductor structure of FIG.16 where two additional metal layers are deposited over the first,second, third, and fourth FETs, in accordance with an embodiment of thepresent invention;

FIG. 18 is a cross-sectional view of the semiconductor structure of FIG.17 where a dummy fill material is deposited, in accordance with anembodiment of the present invention;

FIG. 19 is a cross-sectional view of the semiconductor structure of FIG.18 where the dummy fill material is recessed, in accordance with anembodiment of the present invention;

FIG. 20 is a cross-sectional view of the semiconductor structure of FIG.19 where the remaining work function metals of the first, second, third,and fourth FETs are removed, in accordance with an embodiment of thepresent invention;

FIG. 21 is a cross-sectional view of the semiconductor structure of FIG.20 where the OPL is stripped, in accordance with an embodiment of thepresent invention;

FIG. 22 is a cross-sectional view of the semiconductor structure of FIG.21 where an oxide layer is deposited, in accordance with an embodimentof the present invention;

FIG. 23 is a cross-sectional view of the semiconductor structure of FIG.22 where the oxide layer is recessed to a top surface of the hard maskafter CMP, in accordance with an embodiment of the present invention;

FIG. 24 is a cross-sectional view of the semiconductor structure of FIG.23 where the oxide layer is further recessed and spacers are formedadjacent the hard masks of each of the first, second, third, and fourthFETs, in accordance with an embodiment of the present invention;

FIG. 25 is a cross-sectional view of the semiconductor structure of FIG.24 where isolation patterning is performed between the FETs, inaccordance with an embodiment of the present invention;

FIG. 26 is a cross-sectional view of the semiconductor structure of FIG.25 where an insulator is deposited, in accordance with an embodiment ofthe present invention;

FIG. 27 is a cross-sectional view of the semiconductor structure of FIG.26 where the insulator is recessed up to a top surface of the hard mask,in accordance with an embodiment of the present invention;

FIG. 28 is a cross-sectional view of the semiconductor structure of FIG.27 where etching is performed to expose a channel of each of the first,second, third, and fourth FETs, in accordance with an embodiment of thepresent invention; and

FIG. 29 is a cross-sectional view of the semiconductor structure of FIG.28 where source/drain regions and contacts are formed, in accordancewith an embodiment of the present invention.

Throughout the drawings, same or similar reference numerals representthe same or similar elements.

DETAILED DESCRIPTION

Embodiments in accordance with the present invention provide methods anddevices for achieving multiple work functions on a single structure.Multiple work function gate stacks can be useful to achieve multiplethreshold voltages on fully depleted channel architectures. A variety ofdifferent work-function setting metal stacks can be used. In oneexample, a structure including four FETs is used. Each FET can bedesigned to have a different threshold voltage. Multiple pure metalgates can be formed and similar gate thickness can be used to achieve amulti-Vt structure for FETs. The FETs can be, e.g., vertical FETs. Themulti-layer gate stacks can define the voltage thresholds with differentmetal layers among the voltage thresholds. Moreover, there can be somecommon layers to connect the FETs. However, the work functions need notbe shared between all the FETs. The thickness difference between thegate stacks of the FETs can be, e.g., less than about 3 nm, which can befined-tuned to be even smaller. Thus, a similar gate stack thickness canbe achieved for each Vt structure.

Examples of semiconductor materials that can be used in forming suchmulti-Vt structures include silicon (Si), germanium (Ge), silicongermanium alloys (SiGe), silicon carbide (SiC), silicon germaniumcarbide (SiGeC), III-V compound semiconductors and/or II-VI compoundsemiconductors. III-V compound semiconductors are materials that includeat least one element from Group III of the Periodic Table of Elementsand at least one element from Group V of the Periodic Table of Elements.II-VI compound semiconductors are materials that include at least oneelement from Group II of the Periodic Table of Elements and at least oneelement from Group VI of the Periodic Table of Elements.

As used herein, “semiconductor device” refers to an intrinsicsemiconductor material that has been doped, that is, into which a dopingagent has been introduced, giving it different electrical propertiesthan the intrinsic semiconductor. Doping involves adding dopant atoms toan intrinsic semiconductor, which changes the electron and hole carrierconcentrations of the intrinsic semiconductor at thermal equilibrium.Dominant carrier concentration in an extrinsic semiconductor determinesthe conductivity type of the semiconductor.

A “gate structure” means a structure used to control output current(i.e., flow of carriers in the channel) of a semiconducting devicethrough electrical or magnetic fields.

As used herein, the term “drain” means a doped region in thesemiconductor device located at the end of the channel, in whichcarriers are flowing out of the transistor through the drain.

As used herein, the term “source” is a doped region in the semiconductordevice, in which majority carriers are flowing into the channel.

The term “direct contact” or “directly on” means that a first element,such as a first structure, and a second element, such as a secondstructure, are connected without any intermediary conducting, insulatingor semiconductor layers at the interface of the two elements.

The terms “overlying”, “atop”, “positioned on” or “positioned atop”means that a first element, such as a first structure, is present on asecond element, such as a second structure, wherein interveningelements, such as an interface structure can be present between thefirst element and the second element.

The term “electrically connected” means either directly electricallyconnected, or indirectly electrically connected, such that interveningelements are present; in an indirect electrical connection, theintervening elements can include inductors and/or transformers.

The term “crystalline material” means any material that issingle-crystalline, multi-crystalline, or polycrystalline.

The term “non-crystalline material” means any material that is notcrystalline; including any material that is amorphous, nano-crystalline,or micro-crystalline.

The term “intrinsic material” means a semiconductor material which issubstantially free of doping atoms, or in which the concentration ofdopant atoms is less than 10¹⁵ atoms/cm³.

As used herein, the terms “insulating” and “dielectric” denote amaterial having a room temperature conductivity of less than about 10⁻¹⁰(Ω-m)⁻¹.

As used herein, “p-type” refers to the addition of impurities to anintrinsic semiconductor that creates deficiencies of valence electrons.In a silicon-containing substrate, examples of p-type dopants, i.e.,impurities, include but are not limited to: boron, aluminum, gallium andindium.

As used herein, “n-type” refers to the addition of impurities thatcontributes free electrons to an intrinsic semiconductor. In a siliconcontaining substrate examples of n-type dopants, i.e., impurities,include but are not limited to antimony, arsenic and phosphorous.

The terms, chip, integrated circuit, monolithic device, semiconductordevice, and microelectronic device, are often used interchangeably inthis field. The present invention is applicable to all the above as theyare generally understood in the field.

The terms metal line, interconnect line, trace, wire, conductor, signalpath and signaling medium are all related. The related terms listedabove, are generally interchangeable, and appear in order from specificto general. In this field, metal lines are sometimes referred to astraces, wires, lines, interconnect or simply metal. Metal lines,generally aluminum (Al), copper (Cu) or an alloy of Al and Cu, areconductors that provide signal paths for coupling or interconnectingelectrical circuitry. Conductors other than metal are available inmicroelectronic devices. Materials such as doped polysilicon, dopedsingle-crystal silicon (often referred to simply as diffusion,regardless of whether such doping is achieved by thermal diffusion orion implantation), titanium (Ti), molybdenum (Mo), and refractory metalsilicides are examples of other conductors.

The terms contact and via, both refer to structures for electricalconnection of conductors from different interconnect levels. These termsare sometimes used in the art to describe both an opening in aninsulator in which the structure will be completed, and the completedstructure itself. For purposes of this invention contact and via referto the completed structure.

As used herein, an “anisotropic etch process” denotes a material removalprocess in which the etch rate in the direction normal to the surface tobe etched is greater than in the direction parallel to the surface to beetched. The anisotropic etch can include reactive-ion etching (RIE).

Reactive ion etching (RIE) is a form of plasma etching in which duringetching the surface to be etched is placed on the RF powered electrode.Moreover, during RIE the surface to be etched takes on a potential thataccelerates the etching species extracted from plasma toward thesurface, in which the chemical etching reaction is taking place in thedirection normal to the surface. Other examples of anisotropic etchingthat can be used include ion beam etching, plasma etching or laserablation.

The term “processing” as used herein includes deposition of material orphotoresist, patterning, exposure, development, etching, cleaning,stripping, implanting, doping, stressing, layering, and/or removal ofthe material or photoresist as required in forming a describedstructure.

As used herein, “depositing” can include any now known or laterdeveloped techniques appropriate for the material to be depositedincluding but not limited to, for example: chemical vapor deposition(CVD), low-pressure CVD (LPCVD), plasma-enhanced CVD (PECVD),semi-atmosphere CVD (SACVD) and high density plasma CVD (HDPCVD), rapidthermal CVD (RTCVD), ultra-high vacuum CVD (UHVCVD), limited reactionprocessing CVD (LRPCVD), metal-organic CVD (MOCVD), sputteringdeposition, ion beam deposition, electron beam deposition, laserassisted deposition, thermal oxidation, thermal nitridation, spin-onmethods, physical vapor deposition (PVD), atomic layer deposition (ALD),chemical oxidation, molecular beam epitaxy (MBE), plating, evaporation.

The word “exemplary” is used herein to mean “serving as an example,instance, or illustration.” Any embodiment described herein as“exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments. Likewise, the term “embodiments”does not require that all embodiments include the discussed feature,advantage or mode of operation.

As used herein, the term “about” modifying the quantity of aningredient, component, or reactant of the invention employed refers tovariation in the numerical quantity that can occur, for example, throughtypical measuring and liquid handling procedures used for makingconcentrates or solutions. Furthermore, variation can occur frominadvertent error in measuring procedures, differences in themanufacture, source, or purity of the ingredients employed to make thecompositions or carry out the methods, and the like. In one aspect, theterm “about” means within 10% of the reported numerical value. Inanother aspect, the term “about” means within 5% of the reportednumerical value. Yet, in another aspect, the term “about” means within10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the reported numerical value.

It is to be understood that the present invention will be described interms of a given illustrative architecture; however, otherarchitectures, structures, substrate materials and process features andsteps/blocks can be varied within the scope of the present invention. Itshould be noted that certain features cannot be shown in all figures forthe sake of clarity. This is not intended to be interpreted as alimitation of any particular embodiment, or illustration, or scope ofthe claims.

Various illustrative embodiments of the invention are described below.In the interest of clarity, not all features of an actual implementationare described in this specification. It will of course be appreciatedthat in the development of any such actual embodiment, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which will vary from one implementation toanother. Moreover, it will be appreciated that such a development effortmight be complex and time-consuming, but would nevertheless be a routineundertaking for those of ordinary skill in the art having the benefit ofthis invention.

The present subject matter will now be described with reference to theattached figures. Various structures, systems and devices areschematically depicted in the drawings for purposes of explanation onlyand so as to not obscure the present invention with details that arewell known to those skilled in the art. Nevertheless, the attacheddrawings are included to describe and explain illustrative examples ofthe present invention. The words and phrases used herein should beunderstood and interpreted to have a meaning consistent with theunderstanding of those words and phrases by those skilled in therelevant art. No special definition of a term or phrase, i.e., adefinition that is different from the ordinary and customary meaning asunderstood by those skilled in the art, is intended to be implied byconsistent usage of the term or phrase herein. To the extent that a termor phrase is intended to have a special meaning, i.e., a meaning otherthan that understood by skilled artisans, such a special definition willbe expressly set forth in the specification in a definitional mannerthat directly and unequivocally provides the special definition for theterm or phrase.

FIG. 1 is a cross-sectional view of a semiconductor structure includinga first work function metal layer deposited over first, second, third,and fourth field effect transistors (FETs), in accordance with anembodiment of the present invention.

A semiconductor structure 5 includes a semiconductor substrate 10 with afin structure 16 positioned thereon. The bottom contact 12 is depositedover the substrate 10. The contact 12 can be, e.g., early doped epi orhighly doped Si substrate. An isolation layer (bottom spacer) 14 can bedeposited over the bottom contact 12. STI regions 11 are further formedwithin the contact 12 and extending into the substrate 10. In oneembodiment, a proximal portion of the fin 16 extends into the isolationdielectric layer 14. The fin 16 extend vertically from the substrate 10.Stated differently, the fin 16 is normal to or perpendicular to thesubstrate 10.

A high k dielectric oxide layer 20 is deposited over the fins 16, aswell as over the bottom junction 12. The high k dielectric oxide layer20 encompasses or envelops the fins 16. Additionally, a hard mask 18 canbe deposited or formed over each of the fins 16. The hard mask 18 can bea nitride hard mask or an oxide hard mask. The hard mask 18 is alsoenveloped by the nitride and oxide hard mask. The hard mask 18 isaligned with the fin structure 16.

In one or more embodiments, the substrate 10 can be a semiconductor oran insulator with an active surface semiconductor layer. The substrate10 can be crystalline, semi-crystalline, microcrystalline, or amorphous.The substrate 10 can be essentially (i.e., except for contaminants) asingle element (e.g., silicon), primarily (i.e., with doping) of asingle element, for example, silicon (Si) or germanium (Ge), or thesubstrate 10 can include a compound, for example, Al₂O₃, SiO₂, GaAs,SiC, or SiGe. The substrate 10 can also have multiple material layers,for example, a semiconductor-on-insulator substrate (SeOI), asilicon-on-insulator substrate (SOI), germanium-on-insulator substrate(GeOI), or silicon-germanium-on-insulator substrate (SGOI). Thesubstrate 10 can also have other layers forming the substrate 10,including high-k oxides and/or nitrides. In one or more embodiments, thesubstrate 10 can be a silicon wafer. In an embodiment, the substrate 10is a single crystal silicon wafer.

In one or more embodiments, a first work function conducting layer 22 isdeposited over the high k dielectric oxide layer 20. The first workfunction conducting layer 22 can be, e.g., a first work function metallayer 22. The first work function metal layer 22 can be, e.g., titaniumnitride (TiN). The thickness of the first work function metal layer 22can be about 1 nm to about 4 nm. The thickness of the first workfunction metal layer 22 can be greater than the thickness of the high kdielectric oxide layer 20. The first work function metal layer 22 isdeposited over each of the fins 16. The example embodiment illustratesfour fins 16. Of course, one skilled in the art can contemplate aplurality of fins 16 forming structure 5.

The first fin 16 can be defined in a first region R1, the second fin 16can be defined in a second region R2, the third fin 16 can be defined ina third region R3, and the fourth fin 16 can be defined in a fourthregion R4. The fin of the first region R1 can define an nFET, and inparticular, a super low Vt (SLVT) nFET. The fin of the second region R2can define an nFET, and in particular, a regular Vt (RVT) nFET. The finof the third region R3 can define a pFET, and in particular, a regularVt (RVT) pFET. The fin of the fourth region R4 can define a pFET, and inparticular, a super low Vt (SLVT) pFET.

The “work function” (WF) is the minimum energy (usually measured inelectron volts) needed to remove an electron from a solid to a pointimmediately outside the solid surface (or energy needed to move anelectron from the Fermi energy level into vacuum). Here “immediately”means that the final electron position is far from the surface on theatomic scale but still close to the solid on the macroscopic scale. Thework function is an important property of metals. The magnitude of thework function is usually about a half of the ionization energy of a freeatom of the metal.

WF is a material property of any material, whether the material is aconductor, semiconductor, or dielectric. For a metal, the Fermi levellies within the conduction band, indicating that the band is partlyfilled. For an insulator, the Fermi level lies within the band gap,indicating an empty conduction band; in the case, the minimum energy toremove an electron is about the sum of half the band gap and theelectron affinity. An effective work function (eWF) is defined as the WFof metal on the dielectric side of a metal-dielectric interface.

The WF of a semiconductor material can be altered by doping thesemiconductor material. For example, undoped polysilicon has a workfunction of about 4.65 eV, whereas polysilicon doped with boron has awork function of about 5.15 eV. When used as a gate electrode, the WF ofa semiconductor or conductor directly affects the threshold voltage ofthe transistor.

The WF is a key parameter for setting the threshold voltage (Vth) of thecomplementary metal oxide semiconductor (CMOS) device, whether an n-typefield effect transistor (FET) or a p-type FET. In order to obtain a goodelectrical control of the FET devices, the WF value should be close tothe valence band of the semiconductor for a pFET and close to theconduction band of the semiconductor for an nFET, and more particularly,about 5.2 eV and about 4.0 eV, respectively for the pFET and nFET in thecase of silicon.

Such WF setting metal layers can include, for example, optional layersof about 10 Å to about 30 Å thick titanium nitride and about 10 Å toabout 30 Å thick tantalum nitride, followed by a non-optional about 10 Åto about 40 Å thick layer of titanium aluminum, which together make up aWF setting metal layer portion of the metal gate material stack.Alternatively, titanium aluminum nitride, titanium aluminum carbide,tantalum aluminum, tantalum aluminum nitride, tantalum aluminum carbide,hafnium silicon alloy, hafnium nitride, or tantalum carbide can be usedin the WF setting metal layer portion in lieu of the titanium aluminum.

Regardless of the specific WF setting metal layers used in either annFET or a pFET device, the remainder of the metal gate material stackcan include a fill metal such as aluminum, titanium-doped aluminum,tungsten or copper to result in the metal gate material stack.

ALD is a gas phase chemical process used to create extremely thincoatings. The majority of ALD reactions use two chemicals, typicallycalled precursors. These precursors react with a surface one-at-a-timein a sequential manner. By exposing the precursors to the growth surfacerepeatedly, a thin film is deposited. ALD is a self-limiting, sequentialsurface chemistry that deposits conformal thin-films of materials ontosubstrates of varying compositions. ALD is similar in chemistry tochemical vapor deposition (CVD), except that the ALD reaction breaks theCVD reaction into two half-reactions, keeping the precursor materialsseparate during the reaction. ALD film growth is self-limited and basedon surface reactions, which makes achieving atomic scale depositioncontrol possible. By keeping the precursors separate throughout thecoating process, atomic layer control of film grown can be obtained asfine as ^(˜)0.1 angstroms per monolayer. ALD has unique advantages overother thin film deposition techniques, as ALD grown films are conformal,pin-hole free, and chemically bonded to the substrate. With ALD it ispossible to deposit coatings perfectly uniform in thickness inside deeptrenches, porous media and around particles. The film thickness range isusually about 1-500 nm. ALD can be used to deposit several types of thinfilms, including various ceramics, from conductors to insulators.

In various embodiments, the materials and layers can be deposited byphysical vapor deposition (PVD), chemical vapor deposition (CVD), atomiclayer deposition (ALD), molecular beam epitaxy (MBE), or any of thevarious modifications thereof, for example plasma-enhanced chemicalvapor deposition (PECVD), metal-organic chemical vapor deposition(MOCVD), low pressure chemical vapor deposition (LPCVD), electron-beamphysical vapor deposition (EB-PVD), and plasma-enhanced atomic layerdeposition (PE-ALD). The depositions can be epitaxial processes, and thedeposited material can be crystalline. In various embodiments, formationof a layer can be by one or more deposition processes, where, forexample, a conformal layer can be formed by a first process (e.g., ALD,PE-ALD, etc.) and a fill can be formed by a second process (e.g., CVD,electrodeposition, PVD, etc.).

FIG. 2 is a cross-sectional view of the semiconductor structure of FIG.1 where a patterning block layer (or stack) is deposited and recessedaround the third FET, in accordance with an embodiment of the presentinvention.

In various example embodiments, a patterning block layer (or stack) 24is deposited over the fins 16. A portion of the patterning block layer(or stack) 24 is removed to create a recess 26 in an area surroundingthe third fin 16. The removal of the portion of the patterning blocklayer (or stack) 24 results in a top surface 23 of the first workfunction metal layer 22 being exposed.

FIG. 3 is a cross-sectional view of the semiconductor structure of FIG.2 where the first work function metal layer is removed from the thirdFET, in accordance with an embodiment of the present invention.

In various example embodiments, the first work function metal layer 22is selectively etched or removed from the third fin 16 (pFET RVT).Removal of the first work function metal layer 22 results in a topsurface 21 of the high k dielectric oxide layer 20 being exposed in thethird region R3. Moreover, the first, second, and fourth FETs (nFETSLVT, nFET RVT, and pFET SLVT) have a shared or common layer, that is, afirst work function metal layer 22.

The etching can include a dry etching process such as, for example,reactive ion etching, plasma etching, ion etching or laser ablation. Theetching can further include a wet chemical etching process in which oneor more chemical etchants are used to remove portions of the blanketlayers that are not protected by the patterned photoresist. Thepatterned photoresist can be removed utilizing an ashing process.

As used herein, the term “selective” in reference to a material removalprocess denotes that the rate of material removal for a first materialis greater than the rate of removal for at least another material of thestructure to which the material removal process is being applied. Forexample, in one embodiment, a selective etch can include an etchchemistry that removes a first material selectively to a second materialby a ratio of 10:1 or greater, e.g., 100:1 or greater, or 1000:1 orgreater.

FIG. 4 is a cross-sectional view of the semiconductor structure of FIG.3 where a second work function metal layer is deposited, in accordancewith an embodiment of the present invention.

In various example embodiments, a second work function conducting layer28 is deposited. The second work function conducting layer 28 can be,e.g., a second work function metal layer 28. The second work functionmetal layer 28 can be, e.g., titanium nitride (TiN). The thickness ofthe second work function metal layer 28 can be about 0.5 nm to about 2nm. The second work function metal layer 28 is deposited over each ofthe fins 16.

FIG. 5 is a cross-sectional view of the semiconductor structure of FIG.4 where a patterning block layer (or stack) is deposited and recessedaround the second FET, in accordance with an embodiment of the presentinvention.

In various example embodiments, a patterning block layer (or stack) 30is deposited over the fins 16. A portion of the patterning block layer(or stack) 30 is removed to create a recess 32 in an area surroundingthe second fin 16. The removal of the portion of the patterning blocklayer (or stack) 30 results in a top surface 27 of the second workfunction metal layer 28 being exposed.

FIG. 6 is a cross-sectional view of the semiconductor structure of FIG.5 where the first and second work function metal layers are removed fromthe second FET, in accordance with an embodiment of the presentinvention.

In various example embodiments, the first and second work function metallayers 22, 28 are selectively etched or removed from the second fin 16(nFET RVT). Removal of the first and second work function metal layers22, 28 results in a top surface 21 of the high k dielectric oxide layer20 being exposed in the second region R2. Moreover, the first, third,and fourth FETs (nFET SLVT, pFET RVT, and pFET SLVT) have a shared orcommon layer, that is, a second work function metal layer 28.

FIG. 7 is a cross-sectional view of the semiconductor structure of FIG.6 where a third work function metal layer is deposited, in accordancewith an embodiment of the present invention.

In various example embodiments, a third work function conducting layer34 is deposited. The third work function conducting layer 34 can be,e.g., a third work function metal layer 34. The third work functionmetal layer 34 can be, e.g., titanium nitride (TiN). The thickness ofthe third work function metal layer 34 can be about 0.5 nm to about 1nm. The third work function metal layer 34 is deposited over each of thefins 16.

FIG. 8 is a cross-sectional view of the semiconductor structure of FIG.7 where a patterning block layer (or stack) is deposited and recessedaround the first FET, in accordance with an embodiment of the presentinvention.

In various example embodiments, a patterning block layer (or stack) 36is deposited over the fins 16. A portion of the oxide layer 36 isremoved to create a recess 38 in an area surrounding the first fin 16.The removal of the portion of the oxide layer 36 results in a topsurface 35 of the third work function metal layer 34 being exposed.

FIG. 9 is a cross-sectional view of the semiconductor structure of FIG.8 where the first, second, and third work function metal layers areremoved from the first FET, in accordance with an embodiment of thepresent invention.

In various example embodiments, the first, second, and third workfunction metal layers 22, 28, 34 are selectively etched or removed fromthe first fin 16 (nFET SLVT). Removal of the first, second, and thirdwork function metal layers 22, 28, 34 results in a top surface 21 of thehigh k dielectric oxide layer 20 being exposed in the first region R1.Moreover, the second, third, and fourth FETs (nFET RVT, pFET RVT, andpFET SLVT) have a shared or common layer, that is, a third work functionmetal layer 34.

FIG. 10 is a cross-sectional view of the semiconductor structure of FIG.9 where a fourth work function metal layer is deposited, as well as asacrificial block layer, and a sacrificial cap layer, in accordance withan embodiment of the present invention.

In various example embodiments, a fourth work function conducting layer40 is deposited. The fourth work function conducting layer 40 can be,e.g., a fourth work function metal layer 40. The fourth work functionmetal layer 40 can be, e.g., titanium nitride (TiN). The thickness ofthe fourth work function metal layer 40 can be about 0.5 nm. The fourthwork function metal layer 40 is deposited over each of the fins 16.

Additionally, a sacrificial block layer 42 and a sacrificial cap layer44 are deposited. The sacrificial block layer 42 can have a thickness ofabout 1 nm. The sacrificial cap layer 44 can have a thickness of about 1nm. The sacrificial block layer 42 can be amorphous Si, aluminum oxide(Al₂O₃). The sacrificial cap layer 44 can be, e.g., titanium nitride(TiN). In one embodiment, the layers 42 and 44 could be merged to onelayer, which can be the deposited silicon oxide (SiO₂).

FIG. 11 is a cross-sectional view of the semiconductor structure of FIG.10 where a patterning block layer (or stack) is deposited and recessedaround the first and second FETs, in accordance with an embodiment ofthe present invention.

In various example embodiments, a patterning block layer (or stack) 46is deposited over the fins 16. A portion of the oxide layer 46 isremoved to create recesses 48 in an area surrounding the first andsecond fins 16. The removal of the portion of the oxide layer 46 resultsin a top surface 45 of the sacrificial cap layer 44 being exposed.

FIG. 12 is a cross-sectional view of the semiconductor structure of FIG.11 where the sacrificial cap layer and the sacrificial block layer areremoved from the first and second FETs, in accordance with an embodimentof the present invention.

In various example embodiments, the sacrificial block layer 42 and asacrificial cap layer 44 are selectively etched or removed from thefirst and second fins 16 (nFET SLVT and nFET RVT). Removal of thesacrificial block layer 42 and a sacrificial cap layer 44 results in atop surface 41 of the fourth work function metal layer 40 being exposedin the first and second regions R1, R2. The top surface 45 of thesacrificial cap layer 44 is exposed in the third and fourth regions R3,R4. Moreover, the first, second, third, and fourth FETs (nFET SLVT, nFETRVT, pFET RVT, and pFET SLVT) have a shared or common layer, that is, afourth work function metal layer 40. Thus, all FETs of this structurehave at least one common or shared layer, even though each FET will havea different work function (and different threshold voltage).

FIG. 13 is a cross-sectional view of the semiconductor structure of FIG.12 where an nFET work function metal is deposited, as well as apatterning cap, in accordance with an embodiment of the presentinvention.

In various example embodiments, an nFET work function metal 50 and apatterning cap layer 52 are deposited. The nFET work function metal 50can be, e.g., one of titanium (Ti), aluminum (Al), titanium aluminum(TiAl), titanium aluminum carbon (TiAlC), or any combination of Ti andAl alloys, and can be deposited by, e.g., ALD. The patterning cap layer52 can be, e.g., a TiN layer. The nFET work function metal 50 can have athickness of about 1 nm to about 10 nm. The patterning cap layer 52 canhave a thickness of about 0.5 nm to about 4 nm.

FIG. 14 is a cross-sectional view of the semiconductor structure of FIG.13 where a patterning block layer (or stack) is deposited and recessedaround the third and fourth FETs, in accordance with an embodiment ofthe present invention.

In various example embodiments, a patterning block layer (or stack) 54is deposited over the fins 16. A portion of the oxide layer 54 isremoved to create recesses 53 in an area surrounding the third andfourth fins 16. The removal of the portion of the oxide layer 54 resultsin a top surface 51 of the patterning cap layer 52 being exposed.

FIG. 15 is a cross-sectional view of the semiconductor structure of FIG.14 where the nFET work function metal and the sacrificial cap layer areremoved, in accordance with an embodiment of the present invention.

In various example embodiments, the patterning cap layer 52, the nFETwork function metal 50, and the sacrificial cap layer 44 are selectivelyetched or removed from the third and fourth fins 16 (pFET RVT and pFETSLVT). Removal of such layers results in a top surface 43 of thesacrificial block layer 42 being exposed in the third and fourth regionsR3, R4. The top surface 43 of the sacrificial block layer 42 is exposedin the third and fourth regions R3, R4. The top surface 51 of thepatterning cap layer 52 is exposed in the first and second regions R1,R2. Moreover, the first and second FETs (nFET SLVT and nFET RVT) have ashared or common layer, that is, nFET work function metal 50.

FIG. 16 is a cross-sectional view of the semiconductor structure of FIG.15 where the sacrificial block layer is removed, in accordance with anembodiment of the present invention.

In various example embodiments, the sacrificial block layer 42 is thenremoved to expose a top surface 41 of the fourth work function metallayer 40 extending over the third and fourth regions R3, R4.

FIG. 17 is a cross-sectional view of the semiconductor structure of FIG.16 where two additional metal layers are deposited over the first,second, third, and fourth FETs, in accordance with an embodiment of thepresent invention.

In various example embodiments, a first conducting layer 60 and a secondconducting layer 62 are deposited. The first and second conductinglayers 60, 62 can be, e.g., metal layers. The first conducting layer 60can be one of titanium (Ti), aluminum (Al), titanium aluminum (TiAl),titanium aluminum carbon (TiAlC), or any combination of Ti and Alalloys, whereas the second conducting layer 62 can be, e.g., TiN. Theadditional metal layers 60, 62 can help tune the pFET RVT (e.g., thethird fin in the third region R3). The difference b-a is about 0.5 nm toabout 1 nm. The difference d-c is about 1.5 nm to about 2 nm. Thedifference b-d is about 0 nm and the difference a-c is about 0 nm.Therefore, the thickness difference between the gate stacks is less thanabout 2 nm.

Moreover, the first, second, third, and fourth FETs (nFET SLVT, nFETRVT, pFET RVT, and pFET SLVT) have two shared or common layers, that is,metal layers 60, 62. Additionally, the fourth work function metal layer40 is shared or common for all four FETs. The first work function metallayer 40 is not shared by all the FETs. In fact, the first work functionmetal layer 40 is formed only for the pFET SLVT (far right). The secondwork function metal layer 28 is not shared by all the FETs. In fact, thesecond work function metal layer 28 is shared only with the third andfourth FETs (pFET RVT, and pFET SLVT). The third work function metallayer 34 is not shared by all the FETs. In fact, the third work functionmetal layer 34 is shared only with the second, third, and fourth FETs(nFET RVT, pFET RVT, and pFET SLVT). Therefore, some FETs have shared orcommon layers, whereas other do not. The fourth work metal function 40,e.g., is shared by all four FETs, even though all the FETs havedifferent work functions (and different threshold voltages).

FIG. 18 is a cross-sectional view of the semiconductor structure of FIG.17 where an organic planarization layer (OPL) is deposited, inaccordance with an embodiment of the present invention.

In various example embodiments, an organic planarization layer (OPL) 64is deposited over the fins 16. The OPL 64 can be formed utilizing adeposition process such as, for example, spin-on, CVD, PECVD,evaporation, chemical solution deposition and other like depositiontechniques. The thickness of the OPL 64 can vary so long as itsthickness is greater than the total thickness of each gate line and ofthe plurality of gate lines (not shown). In one embodiment, the OPL 64has a thickness from 50 nm to 500 nm. In another embodiment, the OPL 64has a thickness from 150 nm to 300 nm.

FIG. 19 is a cross-sectional view of the semiconductor structure of FIG.18 where the OPL is recessed, in accordance with an embodiment of thepresent invention.

In various example embodiments, the OPL 64 is recessed below a bottomsurface of the hard mark 18. The OPL 64 is recessed to a level justbelow a top surface/portion of the fins 16. The recessed OPL 66 sitsbetween the fins 16 or between the nFETs and pFETs.

FIG. 20 is a cross-sectional view of the semiconductor structure of FIG.19 where the remaining work function metals of the first, second, third,and fourth FETs are removed, in accordance with an embodiment of thepresent invention.

In various example embodiments, the work function metal layers of eachof the FETs are recessed. Additionally, the high k dielectric oxidelayer 20 is recessed to expose the hard mask 18, as well as a topportion 17 of each fin 16. The top surface 19 and the side surfaces 19′of the hard mask 18 are exposed. The top section of the fins 16 and hardmask 18 exposed is designated as section 68. Moreover, the recessresults in the exposure of the top surface 67 of the recessed OPL 66.

FIG. 21 is a cross-sectional view of the semiconductor structure of FIG.20 where the OPL is stripped, in accordance with an embodiment of thepresent invention.

In various example embodiments, the recessed OPL 66 is removed to exposean inner surface 63 of the metal layer 62.

FIG. 22 is a cross-sectional view of the semiconductor structure of FIG.21 where an oxide layer is deposited, in accordance with an embodimentof the present invention.

In various example embodiments, an encapsulation layer 70 is depositedover the fins 16, as well as within the inner surfaces 63 of the metallayer 62. An oxide layer 72 is then deposited thereon. The oxide layer72 can be an interlevel dielectric (ILD).

In various embodiments, the height of the ILD oxide fill 72 can bereduced by chemical-mechanical polishing (CMP) and/or etching.Therefore, the planarization process can be provided by CMP. Otherplanarization process can include grinding and polishing.

In one or more embodiments, the ILD oxide 72 can have a thickness in therange of about 10 nm to about 100 nm, or in the range of about 10 nm toabout 30 nm.

The ILD 72 can be selected from the group consisting of siliconcontaining materials such as SiO₂, Si₃N₄, SiO_(x)N_(y), SiC, SiCO,SiCOH, and SiCH compounds, the above-mentioned silicon containingmaterials with some or all of the Si replaced by Ge, carbon dopedoxides, inorganic oxides, inorganic polymers, hybrid polymers, organicpolymers such as polyamides or SiLK™, other carbon containing materials,organo-inorganic materials such as spin-on glasses andsilsesquioxane-based materials, and diamond-like carbon (DLC), alsoknown as amorphous hydrogenated carbon, α-C:H). Additional choices forthe ILD 72 include any of the aforementioned materials in porous form,or in a form that changes during processing to or from being porousand/or permeable to being non-porous and/or non-permeable.

FIG. 23 is a cross-sectional view of the semiconductor structure of FIG.22 where the oxide layer is recessed to a top surface of the hard mask,in accordance with an embodiment of the present invention.

In various example embodiments, the ILD oxide 72 can be planarized byCMP, as discussed above. The remaining ILD oxide is designated as 74.The ILD oxide 72 is planarized such that a top surface 71 of theencapsulation layer 70 is exposed. Thus, a top surface 75 of theremaining ILD oxide 74 is flush with the top surface 71 of theencapsulation layer 70.

FIG. 24 is a cross-sectional view of the semiconductor structure of FIG.23 where the oxide layer is further recessed and spacers are formedadjacent the hard masks of each of the first, second, third, and fourthFETs, in accordance with an embodiment of the present invention.

In various example embodiments, the ILD oxide 74 is further recessed toa level that extends up to a top surface of the remaining work functionmetal layers. Stated differently, the recessed ILD oxide 76 extends justbelow a top surface of the fins 16. Additionally, spacers 78 are formedadjacent the top section 68 of the fins 16. The spacers extend to thetop surface 71 of the encapsulation layer 70. The spacers 78 are formedadjacent the hard masks 18. The spacers 78 contact the encapsulationlayer 70.

The spacers 78 can be, e.g., a nitride film. In an embodiment, thespacers 78 can be an oxide, for example, silicon oxide (SiO), a nitride,for example, a silicon nitride (SiN), or an oxynitride, for example,silicon oxynitride (SiON). In an embodiment, the spacers 78 can be,e.g., SiOCN, SiBCN, or similar film types. The spacers 78 can also bereferred to as a non-conducting dielectric layer.

In some exemplary embodiments, the spacers 78 can include a materialthat is resistant to some etching processes such as, for example, HF(hydrogen fluoride) chemical etching or chemical oxide removal etching.For illustrative purposes, the spacers 78 are shown as a single layer ofmaterial. Exemplary embodiments of the spacers 78 can include, forexample, multiple layers of similar or dissimilar materials that can bedisposed in horizontally or vertically arranged layers relative to thesubstrate 10 by any suitable material deposition process.

In one or more embodiments, the spacers 78 can have a thickness in therange of about 3 nm to about 20 nm, or in the range of about 3 nm toabout 10 nm.

FIG. 25 is a cross-sectional view of the semiconductor structure of FIG.24 where isolation patterning is performed between the FETs, inaccordance with an embodiment of the present invention.

In various example embodiments, the FETs are isolated by an isolationpatterning technique, such as RIE. The etching results in the exposureof a top surface 15 of the isolation dielectric layer. Thus, the fins 16(or FETs) are separated by recesses 80 by self-alignment.

FIG. 26 is a cross-sectional view of the semiconductor structure of FIG.25 where an insulator is deposited, in accordance with an embodiment ofthe present invention.

In various example embodiments, an insulator 82 is deposited over theFETs such that the recesses 80 are filled with the insulator 82.Additionally, the insulator 82 covers the entirety of the spacers 78.

FIG. 27 is a cross-sectional view of the semiconductor structure of FIG.26 where the insulator is recessed up to a top surface of the hard mask,in accordance with an embodiment of the present invention.

In various example embodiments, the insulator 82 is planarized by, e.g.,CMP. The planarization results in the top surface 71 of theencapsulation layer 70 being exposed. The top surface 85 of the recessedinsulator 84 is flush with the top surface 71 of the encapsulation layer70.

FIG. 28 is a cross-sectional view of the semiconductor structure of FIG.27 where etching is performed to expose a channel of each of the first,second, third, and fourth FETs, in accordance with an embodiment of thepresent invention.

In various example embodiments, a non-selective RIE is performed toexpose a top section 87 of the fins 16 of each of the FETs. Thus, thechannel material of each of the FETs is exposed.

FIG. 29 is a cross-sectional view of the semiconductor structure of FIG.28 where source/drain regions and contacts are formed, in accordancewith an embodiment of the present invention.

In various example embodiments, top source/drain regions 90 are formedover each of the channels or FETs or fins 16. Contacts 92 and 96 canthen be formed. The contacts 92 are formed over the top source/drainregions 90, whereas the contact 96 extends to the substrate 10. Aninsulator 94 can also be deposited between the contacts 92. Theinsulator 94 can be planarized by, e.g., CMP to be flush with a topsurface of the contacts 92, 96. As a result, the pFET RVT and the nFETRVT can have a shared/common gate structure. Similarly, the pFET SLVTand the nFET SLVT can have a shared/common gate structure. Moreover, apure multi-Vt scheme can be combined with a dipole multi-Vt scheme toprovide for more Vt options without channel doping.

By similar reason, this pure work function metal scheme can also be usedin a replacement metal gate to set up the multi-Vt scheme.

Consequently, the structure of FIG. 29 allows for the work function ofselected transistors to be fine-tuned. This results in a final structurehaving four different work functions. As a result, multiple workfunctions can be achieved for different devices on the same wafer/chip.The work function difference is provided by selectively applyingdifferent work function metals in between a variety of patterning stepsthroughout the manufacturing process. As a result, the gate stack ofeach FET can have a different work function to achieve complementarymetal oxide semiconductor (CMOS) technology with multiple thresholdvoltages (Vt) on fully depleted channel architectures in order to takeadvantage of higher mobility and smaller device variability. Thus,multiple voltage thresholds by pure metal gates can offer betterperformance and better mismatch because of mobility enhancement due toless doping or no doping in the channel. The multi-layer gate stacks canthus define the voltage thresholds.

It is to be understood that the present invention will be described interms of a given illustrative architecture; however, otherarchitectures, structures, substrate materials and process features andsteps/blocks can be varied within the scope of the present invention.

It will also be understood that when an element such as a layer, regionor substrate is referred to as being “on” or “over” another element, itcan be directly on the other element or intervening elements can also bepresent. In contrast, when an element is referred to as being “directlyon” or “directly over” another element, there are no interveningelements present. It will also be understood that when an element isreferred to as being “connected” or “coupled” to another element, it canbe directly connected or coupled to the other element or interveningelements can be present. In contrast, when an element is referred to asbeing “directly connected” or “directly coupled” to another element,there are no intervening elements present.

The present embodiments can include a design for an integrated circuitchip, which can be created in a graphical computer programming language,and stored in a computer storage medium (such as a disk, tape, physicalhard drive, or virtual hard drive such as in a storage access network).If the designer does not fabricate chips or the photolithographic masksused to fabricate chips, the designer can transmit the resulting designby physical mechanisms (e.g., by providing a copy of the storage mediumstoring the design) or electronically (e.g., through the Internet) tosuch entities, directly or indirectly. The stored design is thenconverted into the appropriate format (e.g., GDSII) for the fabricationof photolithographic masks, which typically include multiple copies ofthe chip design in question that are to be formed on a wafer. Thephotolithographic masks are utilized to define areas of the wafer(and/or the layers thereon) to be etched or otherwise processed.

Methods as described herein can be used in the fabrication of integratedcircuit chips. The resulting integrated circuit chips can be distributedby the fabricator in raw wafer form (that is, as a single wafer that hasmultiple unpackaged chips), as a bare die, or in a packaged form. In thelatter case, the chip is mounted in a single chip package (such as aplastic carrier, with leads that are affixed to a motherboard or otherhigher level carrier) or in a multichip package (such as a ceramiccarrier that has either or both surface interconnections or buriedinterconnections). In any case, the chip is then integrated with otherchips, discrete circuit elements, and/or other signal processing devicesas part of either (a) an intermediate product, such as a motherboard, or(b) an end product. The end product can be any product that includesintegrated circuit chips, ranging from toys and other low-endapplications to advanced computer products having a display, a keyboardor other input device, and a central processor.

It should also be understood that material compounds will be describedin terms of listed elements, e.g., SiGe. These compounds includedifferent proportions of the elements within the compound, e.g., SiGeincludes Si_(x)Ge_(1-x) where x is less than or equal to 1, etc. Inaddition, other elements can be included in the compound and stillfunction in accordance with the present embodiments. The compounds withadditional elements will be referred to herein as alloys.

Reference in the specification to “one embodiment” or “an embodiment” ofthe present invention, as well as other variations thereof, means that aparticular feature, structure, characteristic, and so forth described inconnection with the embodiment is included in at least one embodiment ofthe present invention. Thus, the appearances of the phrase “in oneembodiment” or “in an embodiment”, as well any other variations,appearing in various places throughout the specification are notnecessarily all referring to the same embodiment.

It is to be appreciated that the use of any of the following “/”,“and/or”, and “at least one of”, for example, in the cases of “A/B”, “Aand/or B” and “at least one of A and B”, is intended to encompass theselection of the first listed option (A) only, or the selection of thesecond listed option (B) only, or the selection of both options (A andB). As a further example, in the cases of “A, B, and/or C” and “at leastone of A, B, and C”, such phrasing is intended to encompass theselection of the first listed option (A) only, or the selection of thesecond listed option (B) only, or the selection of the third listedoption (C) only, or the selection of the first and the second listedoptions (A and B) only, or the selection of the first and third listedoptions (A and C) only, or the selection of the second and third listedoptions (B and C) only, or the selection of all three options (A and Band C). This can be extended, as readily apparent by one of ordinaryskill in this and related arts, for as many items listed.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of exampleembodiments. As used herein, the singular forms “a,” “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises,” “comprising,” “includes” and/or “including,” when usedherein, specify the presence of stated features, integers, steps,operations, elements and/or components, but do not preclude the presenceor addition of one or more other features, integers, steps, operations,elements, components and/or groups thereof.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,”“upper,” and the like, can be used herein for ease of description todescribe one element's or feature's relationship to another element(s)or feature(s) as illustrated in the FIGS. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the FIGS. For example, if the device in theFIGS. is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the term “below” can encompass both an orientation ofabove and below. The device can be otherwise oriented (rotated 90degrees or at other orientations), and the spatially relativedescriptors used herein can be interpreted accordingly. In addition, itwill also be understood that when a layer is referred to as being“between” two layers, it can be the only layer between the two layers,or one or more intervening layers can also be present.

It will be understood that, although the terms first, second, etc. canbe used herein to describe various elements, these elements should notbe limited by these terms. These terms are only used to distinguish oneelement from another element. Thus, a first element discussed belowcould be termed a second element without departing from the scope of thepresent concept.

Having described preferred embodiments of a method of device fabricationand a semiconductor device thereby fabricated for achieving multi-layerwork function metal gates with similar gate thickness to further achievedifferent threshold voltages for each field effect transistor (FET)(which are intended to be illustrative and not limiting), it is notedthat modifications and variations can be made by persons skilled in theart in light of the above teachings. It is therefore to be understoodthat changes may be made in the particular embodiments described whichare within the scope of the invention as outlined by the appendedclaims. Having thus described aspects of the invention, with the detailsand particularity required by the patent laws, what is claimed anddesired protected by Letters Patent is set forth in the appended claims.

What is claimed is:
 1. A structure for forming a device having multiplefield effect transistors (FETs) with each FET having a different workfunction, the structure comprising: first, second, third, and fourthFETs formed over a semiconductor substrate; an interfacial layer and ahigh-k dielectric layer formed over the first, second, third, and fourthFETs; a first work function conducting layer formed over the high-kdielectric layer, where the first work function conducting layer issubsequently removed from the third FET; a second work functionconducting layer, where the first and second work function conductinglayers are subsequently removed from the second FET; a third workfunction conducting layer, where the first, second, and third workfunction conducting layers are subsequently removed from the first FET;a fourth work function conducting layer; a sacrificial block layer and asacrificial cap layer, the sacrificial block layer and the sacrificialcap layer subsequently removed from the first and second FETs; a fifthwork function conducting layer and a patterning cap layer, where thepatterning cap layer, the fifth work function conducting layer, thesacrificial cap, and the sacrificial block layer are subsequentlyremoved from the third and fourth FETs; and first and second conductinglayers formed over the first, second, third, and fourth FETs.
 2. Thestructure of claim 1, wherein an organic planarization layer (OPL) isdeposited and subsequently recessed.
 3. The structure of claim 2,wherein the remaining work function conducting layers from the first,second, third, and fourth FETs are recessed to expose a hard mask ofeach of the first, second, third, and fourth FETs.
 4. The structure ofclaim 3, wherein the OPL is stripped.
 5. The structure of claim 4,wherein a dielectric layer is deposited up to a top surface of the hardmask of each of the first, second, third, and fourth FETs.
 6. Thestructure of claim 5, wherein the dielectric layer is recessed andspacers are formed.
 7. The structure of claim 6, wherein isolationpatterning of the first, second, third, and fourth FETs is performed. 8.The structure of claim 7, wherein an insulator is deposited between therecesses formed by the isolation patterning.
 9. The structure of claim8, wherein a top portion of a channel of each of the first, second,third, and fourth FETs is exposed by etching.
 10. The structure of claim9, wherein source and/or drain regions and contacts are formed over thechannel of each of the first, second, third, and fourth FETs.
 11. Astructure for forming a device having a plurality of field effecttransistors (FETs) with each FET having a different work function, thestructure comprising: at least one dielectric layer formed over theplurality of FETs; a first work function conducting layer formed overthe at least one dielectric layer, where the first work functionconducting layer is subsequently removed from a first FET; a second workfunction conducting layer, where the first and second work functionconducting layers are subsequently removed from a second FET; a thirdwork function conducting layer, where the first, second, and third workfunction conducting layers are subsequently removed from a third FET; afourth work function conducting layer; at least one sacrificial layer,where the at least one sacrificial layer is subsequently removed fromthe second and third FETs; a fifth work function conducting layer, wherethe fifth work function conducting layer and the at least onesacrificial layer are subsequently removed from at least the first FET;and at least one conducting layer formed over the plurality of FETs;wherein multi-layer work function metal gates of each of the pluralityof FETs have a similar gate thickness.
 12. The structure of claim 11,wherein an organic planarization layer (OPL) is deposited andsubsequently recessed.
 13. The structure of claim 12, wherein theremaining work function conducting layers from the plurality of FETs arerecessed to expose a hard mask of each of the plurality of FETs.
 14. Thestructure of claim 13, wherein the OPL is stripped.
 15. The structure ofclaim 14, wherein a dielectric layer is deposited up to a top surface ofthe hard mask of each of the plurality of FETs.
 16. The structure ofclaim 15, wherein the dielectric layer is recessed and spacers areformed.
 17. The structure of claim 16, wherein isolation patterning ofthe plurality of FETs is performed.
 18. The structure of claim 17,wherein an insulator is deposited between the recesses formed by theisolation patterning.
 19. The structure of claim 18, wherein a topportion of a channel of each of the plurality of FETs is exposed byetching.
 20. The structure of claim 19, wherein source and/or drainregions and contacts are formed over the channel of each of theplurality of FETs.